Spout assembly having a barrier film for a flexible bag and a flexible bag having a spout assembly having a barrier film

ABSTRACT

A spout assembly including a spout, a base film and a coupling member. The spout has a base flange and an upstand. The base flange has a top surface, a lower surface and an outer surface. The upstand extends from the base flange toward a distal end spaced therefrom. The upstand defines a passageway with a lower opening and an upper opening. The base film has a top surface and a bottom surface. At least a portion of the top surface of the base film overlies at least a portion of the lower surface of the base flange. The coupling member couples the base film to the spout. In turn, the base film is maintained in the overlying orientation.

CROSS-REFERENCE TO RELATED APPLICATION

Not Applicable

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

The disclosure relates in general to flexible packaging, and more particularly, to a spout assembly for a flexible bag that includes a barrier film which reduces the oxygen transmission rate therethrough. The disclosure is also directed to a flexible bag having a spout with a barrier film coupled thereto.

2. Background Art

The use of flexible packaging is known in the art. Often the flexible packaging comprises a flexible bag having a spout that is positioned within an outer rigid container (such as a box). Often such packaging is termed bag in box packaging. In some instances, the box can be eliminated and the flexible bag may be a standalone component or may be incorporated into another package (such as a semi-rigid package, for example).

The flexible bag typically contains a flowable material such as a liquid, a syrup, a juice, a gel or the like. In many configurations, a tap is coupled to the spout to allow for the selective dispensing of the flowable material from within the bag. In other configurations, a cap may be positioned over the spout, wherein the cap includes a valve that can be actuated to control the egress of flowable material. In still other configurations, a valve may be positioned within the spout, and the valve can be actuated by a dispenser coupled to the spout. The disclosure is not limited to any particular type of means of fluid withdrawal from the flexible bag.

In many instances, the flowable material is sensitive to outside gasses and materials. For example, the flowable material is susceptible to spoilage, and degradation in quality due to oxidation. Oxidation occurs when oxygen is transmitted through the bag, the spout and the tap of the flexible bag and is directed into the flowable material. One particular beverage that is susceptible to degradation from oxygen exposure is wine. It is often the case that wine is stored in a bag in box package. Therefore, the shelf life of wine packaged in such bag in box packaging is often limited by the oxygen transmission rate of the flexible bag and its components. Decreasing the oxygen transmission rate serves to increase the shelf life of the wine within the bag in box package.

Problematically, changes to the materials and the configuration of the components of the flexible bag are difficult to undertake. First, as the components are coupled together, a level of compatibility for coupling must be insured. In addition, in addition to compatibility, it is necessary to achieve adequate strength in the connections and couplings. Furthermore, utilizing different compounds and materials for the different components may have an impact on the taste or other attribute of the flowable material. Thus, any changes to the materials of the components requires extensive testing.

SUMMARY OF THE DISCLOSURE

The disclosure is directed to a spout assembly comprising spout, a base film and a coupling member. The spout has a base flange and an upstand. The base flange has a top surface, a lower surface and an outer surface. The upstand extends from the base flange toward a distal end spaced therefrom. The upstand defines a passageway with a lower opening and an upper opening. The base film has a top surface and a bottom surface. At least a portion of the top surface of the base film overlies at least a portion of the lower surface of the base flange. The coupling member couples the base film to the spout. In turn, the base film is maintained in the overlying orientation.

In some configurations, the coupling member is structurally configured to couple the base film directly to the spout.

In some configurations, the coupling member is structurally configured to couple the top surface of the base film directly to the lower surface of the base flange.

In some configurations, the coupling member comprises an adhesive joining the top surface of the base film to the lower surface of the base flange.

In some configurations, the coupling member comprises at least one seal sealingly joining the top surface of the base film to the lower surface of the base flange.

In some configurations, the base film includes an inner annular edge and an outer annular edge. The coupling member comprises an inner seal and an outer seal spaced apart from each other. The inner seal is proximate the inner annular edge and the outer seal is proximate the outer annular edge.

In some configurations, the coupling member couples substantially the entirety of the top surface of the base film and the lower surface of the base flange which overlie each other.

In some configurations, the coupling member comprises an inner seal positioned on the bottom surface between an inner annular edge and a projection of the upstand of the spout on the bottom surface, and the outer seal is positioned so as to extend beyond a seal of a film of a bag to the top surface of the base flange.

In some configurations, the base film extends beyond the outer surface of the base flange.

In some configurations, the spout is selected from a polyolefin from the group consisting of EMA, EVA, LDPE, LLDPE, MDPE, HDPE or PP. The base film includes at least one barrier material from the group consisting of EVOH, PET, PETG, PEN, PBT, PA, PVDC, MXD-6, LCP, PAN and SAN. Of course, other materials are contemplated for use.

In some embodiments, the base film includes at least one barrier material from the group consisting of EVOH, PET, PETG, PEN, PBT, PA, PVDC, MXD-6, LCP, PAN and SAN.

In some embodiments, the upstand further comprises a substantially circular cross-sectional configuration.

In another aspect of the disclosure, the disclosure is directed to a flexible bag assembly comprising a flexible bag and a spout assembly. The flexible bag has a plurality of panels that are coupled together with a plurality of seals to form a substantially fluid tight cavity. An opening provides ingress into the cavity. The spout assembly comprises a spout, a base film and a coupling member. The spout has a base flange and an upstand. The base flange has a top surface, a lower surface and an outer surface. The upstand extends from the base flange toward a distal end spaced therefrom. The upstand defines a passageway with a lower opening and an upper opening. The base film has a top surface and a bottom surface. At least a portion of the top surface of the base film overlies at least a portion of the lower surface of the base flange. The coupling member couples the base film to the spout. In turn, the base film is maintained in the overlying orientation.

In some configurations, the coupling member couples the base film to at least one of the lower surface of the base flange, an inner surface of the upstand and a portion of the at least one panel surrounding the opening of the flexible bag.

In some configurations, the base film extends beyond the outer surface of the base flange and overlies a portion of an inner surface of the at least one panel about the opening of the flexible bag.

In some configurations, the base film overlies substantially the entirety of the lower surface of the base flange.

In some configurations, the coupling member is structurally configured to couple the base film directly to the spout.

In some configurations, the coupling member is structurally configured to couple the top surface of the base film directly to the lower surface of the base flange.

In some configurations, the coupling member comprises an adhesive joining the top surface of the base film to the lower surface of the base flange.

In some configurations, the coupling member comprises an inner seal positioned on the bottom surface between an inner annular edge and a projection of the upstand of the spout on the bottom surface, and the outer seal is positioned so as to extend beyond a seal of a film of a bag to the top surface of the base flange.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will now be described with reference to the drawings wherein:

FIG. 1 of the drawings is top plan view of a flexible package of the present disclosure, showing, in particular the barrier spout of the present disclosure;

FIG. 2 of the drawings is a cross-sectional view of the flexible package of the present disclosure, showing, in particular the barrier spout of the present disclosure;

FIG. 3 of the drawings is a perspective view of a spout assembly of the present disclosure, showing a base film coupled thereto through a coupling member;

FIG. 4 of the drawings is a cross-sectional view of the spout assembly shown in FIG. 3;

FIG. 5 of the drawings is a side elevational view of the spout assembly shown in FIG. 3; and

FIG. 6 of the drawings is a bottom plan view of the spout assembly shown in FIG. 3, showing in particular, the configuration of the coupling member;

DETAILED DESCRIPTION OF THE DISCLOSURE

While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and described herein in detail a specific embodiment with the understanding that the present disclosure is to be considered as an exemplification and is not intended to be limited to the embodiment illustrated.

It will be understood that like or analogous elements and/or components, referred to herein, may be identified throughout the drawings by like reference characters. In addition, it will be understood that the drawings are merely schematic representations of the invention, and some of the components may have been distorted from actual scale for purposes of pictorial clarity.

Referring now to the drawings and in particular to FIG. 1, a flexible bag assembly of the present disclosure is shown generally at 10. The flexible bag assembly 10 includes flexible bag 12 and spout assembly 14. The bag assembly is often placed within a rigid outer container, often termed a bag-in-box package. Such packaging is often utilized for different flowable materials, such as, including, but not limited to, chemicals, detergents, drink syrups, mixes, purees, gels and the like. Typically, a dispensing fitment is coupled to the spout, such as a tap or a cap with a valve.

It will be understood that any number of different members may be coupled to the spout assembly 14 when the flexible bag assembly is configured for dispensing, shipping and/or storage. For example, a cap or a dispensing fitment may be coupled to the above configuration. Such connectors may include those disclosed in U.S. Pat. No. 7,387,277 issued to Verespej et al, U.S. Pat. No. 7,469,522 issued to Verespej et al, U.S. Pat. No. 7,114,625 issued to Jones, et al, U.S. Pat. No. 8,448,799 issued to Thurman, as well as various Quick connect, disconnect fittings (QCD) that are utilized in association with soft drink syrups among others. It is also contemplated that dispensers such as those disclosed in U.S. Pat. Nos. 4,619,377 and 6,978,981 both of which are issued to Roos as well as U.S. Pat. Nos. 6,045,119; 6,296,157 and 6,360,925 issued to Erb, U.S. Pat. No. 8,336,743 issued to Bellmore, U.S. Pat. No. 7,240,811 issued to Roser may be utilized. Additionally, it will be understood that the spout or the cavity may further include different structures to aid in the dispensing of flowable material.

The flexible bag 12 may comprise any number of different configurations and different materials. For example, and not limited thereto, the flexible bag 12 is shown in FIGS. 1 and 2 as comprising a pillow type bag formed from a single ply or multiple plies of polymer based film (which may be metallized or otherwise treated). Such a bag includes front panel 80 and back panel 82. Front panel 80 includes outer surface 90 and inner surface 91. The back panel 82 includes outer surface 92 and inner surface 93. The front and back panel are positioned in an overlying orientation so that the inner surfaces face each other. It will be understood that while a generally rectangular inner bag is shown, a bag of a different shape, such as a shape that mates with the cavity portion of the outer soft box may be utilized.

The panels are then coupled together by way of seals 84. In the case of a pillow type container, the seals 84 include a top seal 94, bottom seal 95, first side seal 96 and second side seal 97. The seals are generally perpendicular to adjacent seals and parallel to opposing seals to generally define a square or rectangular configuration, thereby defining a generally square or rectangular cavity 99. The seals may be formed through the application of heat, or through other procedures, including, but not limited to RF welding, ultrasonic welding, adhesive, among others. The disclosure is not limited to any particular manner of attachment of the panels.

For many pillow type containers, an opening 86 is provided through the front panel 80 proximate, but spaced apart from, the bottom seal 95. As will be explained below, the spout assembly 14 can be coupled thereto in sealed engagement by way of seal 87 (which is also represented by a dashed line, while the seal is continuous, in FIG. 6). In certain embodiments, multiple spouts may be provided, one, for example, for dispensing, and one for filling.

The spout assembly 14 is shown in more detail in FIGS. 3 through 6 as comprising spout 16, base film 17 and coupling member 18. The spout 16 includes base flange 20, cylindrical upstand 22, body flange 24 and upper annular rim flange 26. The base flange 20 lower surface 34, top surface 33 and outer surface 32. As will be understood to those of skill in the art, the base flange is coupled to the container body (i.e., typically a conventional pillow-type container) through welding, adhesion or other system typically joining the upper surface to the inside of the panels.

The cylindrical upstand 22 extends upwardly and generally orthogonally from the base flange 20, and through the opening 86 of the flexible bag and includes a proximal end 40 and distal end 41. Typically, the cylindrical upstand is substantially uniform in cross-section and the inner surface defines a passageway with an opening at either end which provides fluid communication with the cavity of the flexible bag. An upper opening is positioned at the distal end, and a lower opening is positioned at the proximal end. While termed cylindrical, elliptical as well as other shapes are contemplated.

The body flange 24 includes upper surface 50, lower surface 51 and outer surface 52. The lower body flange is spaced apart from the base flange and is generally parallel thereto. Thus, a generally uniform lower channel 35 is defined between the flanges. Filling equipment and dispensing coupling equipment may be configured to grasp the spout 14 about the geometry defined by the defined lower channel and the associated flanges. In the embodiment shown, the body flange is of a diameter smaller than the base flange. It will be understood that variations are contemplated.

The upper annular rim flange 26 extends about the distal end of the cylindrical upstand 22. In the embodiment shown, the upper annular rim flange 26 includes upper surface 60, lower surface 61 and outer surface 62. The upper annular rim is positioned at or near the distal end 41 of the cylindrical upstand. In the configuration shown, the upper annular rim is positioned at the uppermost end of the cylindrical upstand and defines the distal end of the spout.

Preferably, the spout is molded from a polymer. Preferably, the spout is formed from a polyolefin, such as, EMA, EVA, LDPE, LLDPE, MDPE, HDPE or PP, while not being limited thereto. The foregoing may have a component used to promote adhesion to a barrier material, for example, and without limitation, anhydride-modified polyolefin.

The base film 17 is shown in FIGS. 4 through 6 as comprising a top surface 70, bottom surface 71, inner annular edge 72 and outer annular edge 73. The base film comprises a film that has barrier properties that are improved over those from which the spout is formed. For example, a co-extrusion having EVOH is contemplated for use, as are films having a barrier material such as EVOH, PET, PETG, PEN, PBT, PA, PVDC, MXD-6, LCP, PAN and SAN. Preferably, the base film 17 is substantially uniform and of a thickness of approximately between 0.5 mils and 10 mils.

It will be understood that the top surface 70 of the base film overlies the lower surface 34 of the base flange 20. In the configuration shown, the base film extends beyond the outer surface 32 of the base flange, and extends to the inner opening of the base flange proximate the cylindrical upstand 22. In turn, the base film covers virtually the entirety of the lower surface of the spout, and even extends therebeyond. In other embodiments, the base film may be smaller or larger than the base flange. That is, the base flange may extend into the opening of the cylindrical upstand 22 and may extend beyond the outer surface 32 of the base flange.

The base film is coupled to the base flange through a coupling member 18. In the embodiment shown, the coupling member 18 comprises a plurality of seals (heat welding, RF sealing, etc.), including, outer seal 83 and inner seal 81. Each of the seals comprises a generally circular seal member which is continuous and extends about the base flange. One of the seals extends proximate the outer surface of the base flange, with the other seal extending proximate the opening in the base flange. Additional seal points or seal surfaces may be disposed between the inner and outer seals. In the configuration shown, the seals comprise heat seals. In other configurations, the seals may comprise adhesive seals or the like. That is, the base film may be adhered to the base flange about discrete locations or about the entirety of the surface of the base flange and/or the base film.

So as to achieve the desired oxygen barrier properties, it is desirable to have the outer seal 83 extend axially to the outside of the spout seal 87 so that the spout seal 87 is maintained within the outer seal 83. Of course, portions thereof may overlap with the spout seal 87, however, preferably at least a portion of the outer seal 83 extends outwardly beyond the spout seal entirely about the circumference of the spout seal. As for the inner seal 81, preferably, the inner seal is positioned at the proximal end of the cylindrical upstand along the lower surface of the spout 16 between the projection of the outer surface 42 and the inner surface 43 of the cylindrical upstand 22. Such a configuration of the inner and outer seals greatly enhances the barrier properties of the base flange. It is preferred that both the seal 81 and 83 are continuous around the base flange of the spout, as, the lower surface of the base flange captured between the seals 81, 83 is therefore physically inaccessible except through the permeability of the base film itself. The seals are not limited to any particular shape or configuration. That is, in the embodiment shown, the seals comprise uniform circular seals that have a substantially uniform width. Other embodiments are contemplated wherein the seals may have configurations that are varied therealong, or that may change is shape about the base flange. It will be understood that the configurations may comprise the joining of the base film to the spout through heat, RF sealing, adhesive, as well as combinations of the foregoing.

In operation, the spout is provided. The spout may comprise the configuration shown, however, it will be understood that other configurations of the spout are contemplated, including, but not limited to spouts that have additional flanges, upstands having different shapes, other outlets, among other features. The spout generally includes a base flange which has an upper surface which is coupled to the inside of the flexible bag.

Once the spout is provided, a base film can be provided in the shape desired to match the shape of the base flange. It will be understood that by matching, it is meant that the shape of the base film may be larger or smaller than the lower surface of the base flange; that is, the base film may extend beyond the base flange either beyond the outer surface or beyond and into the opening where the base flange and the cylindrical upstand meet. It will be further understood that the base film may extend into the cylindrical upstand and be coupled with the coupling member to the inner surface of the cylindrical upstand.

While it is contemplated that the base film is substantially planar, it is contemplated that the base film may be preshaped into a desired configuration which is non-planar. For example, the inner annular edge may be shaped so as to extend into the cylindrical upstand. In other configurations, the outer annular edge may be shaped so as to partially encircle the outer surface 32 of the base flange 20. In still other embodiments, embossings or other surface variations may be introduced into the base film so as to achieve certain separation channels between the base film and the inner surface of the back panel of the flexible bag.

The base film, once provided, is coupled to the spout by way of the coupling member. As explained above, a number of different procedures may be utilized to couple the base film to the spout, and the points or regions of coupling may be varied depending on the application or the configuration desired.

Next, the film for the flexible bag is provided and the opening 86 is defined in the film. This may occur before or after some of the seals joining the front and back panel of the flexible bag have been formed. The cylindrical upstand 22 is extended from the opening of the bag. Once positioned, the top surface 33 of the base flange 20 is coupled to the flexible bag about the opening 86 to form a substantially fluid-tight configuration therewith. A number of coupling methods that are known to those of skill in the art can be utilized, including but not limited to RF welding, heat welding, ultrasonic welding, adhesion and the like. It is envisioned that the outer annular edge may be further coupled to the inner surface of the front panel 80 of the flexible bag through adhesion, sealing or the like.

Advantageously, with the inclusion of the base film, the oxygen transmission rate of the overall flexible bag can be greatly reduced with a very slight modification to the spout. In particular, tests were undertaken of the oxygen transmission of a conventional tap and spout combination as compared to the same tap and spout combination wherein the spout included a base film of the type disclosed above. In particular, the oxygen transmission of the combination was recorded in cc/pkg/day@100% O₂. The results are shown below. Again, the only difference was the inclusion of the base film and the coupling member coupling the base film to the base flange of the spout.

No Barrier Film Applied to Base Film Applied to Base Base Flange Flange Sample cc/pkg/day@100% O₂ cc/pkg/day@100% O₂ 1 0.49 0.30 2 0.50 0.31 3 0.52 0.33 Average 0.50 0.31

As can be seen from the results, the inclusion of the base film coupled by way of the coupling member to the lower surface of the base flange reduced the oxygen transmission by almost forty percent. Such a vast improvement is realized even though only the lower surface of the base flange is covered with the base film and the predominant portion of the cylindrical upstand and the tap remain in the same condition in the second test as they are in the first test. Thus, a vast improvement in the oxygen transmission rate is achieved through the inclusion of the base film. An additional advantage is that the spout and the flexible bag can remain the same and may not require modification. That is, the materials in the spout can remain the same, as can the materials for the flexible bag, as well as the construction and mating. Additionally, as the base film is generally not subjected to the same rigors as a seal between the panels of the flexible bag and between the spout and the flexible bag, the coupling member strength can be substantially less than that of the other seals and joints. In turn, a larger scope of materials become available for use due to the fact that such strengths are not required.

The foregoing description merely explains and illustrates the invention and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the invention. 

What is claimed is:
 1. A spout assembly comprising: a spout having: a base flange with a top surface, a lower surface and an outer surface; an upstand extending from the base flange toward a distal end spaced therefrom, the upstand defining a passageway with a lower opening and an upper opening; a base film having: a top surface; a bottom surface, wherein at least a portion of the top surface of the base film overlies at least a portion of the lower surface of the base flange; and a coupling member coupling the base film to the spout, to, in turn, maintain the base film in the overlying orientation.
 2. The spout assembly of claim 1 wherein the coupling member is structurally configured to couple the base film directly to the spout.
 3. The spout assembly of claim 2 wherein the coupling member is structurally configured to couple the top surface of the base film directly to the lower surface of the base flange.
 4. The spout assembly of claim 2 wherein the coupling member comprises an adhesive joining the top surface of the base film to the lower surface of the base flange.
 5. The spout assembly of claim 2 wherein the coupling member comprises at least one seal sealingly joining the top surface of the base film to the lower surface of the base flange.
 6. The spout assembly of claim 5 wherein the base film includes an inner annular edge and an outer annular edge, the coupling member comprises an inner seal and an outer seal spaced apart from each other, the inner seal being proximate the inner annular edge and the outer seal being proximate the outer annular edge.
 7. The spout assembly of claim 2 wherein the coupling member couples substantially the entirety of the top surface of the base film and the lower surface of the base flange which overlie each other.
 8. The spout assembly of claim 2 wherein the coupling member comprises an inner seal positioned on the bottom surface between an inner annular edge and a projection of the upstand of the spout on the bottom surface, and the outer seal is positioned so as to extend beyond a seal of a film of a bag to the top surface of the base flange.
 9. The spout assembly of claim 1 wherein the base film extends beyond the outer surface of the base flange.
 10. The spout assembly of claim 1 wherein the spout is selected from a polyolefin from the group consisting of EMA, EVA, LDPE, LLDPE, MDPE, HDPE or PP and the base film includes at least one barrier material from the group consisting of EVOH, PET, PETG, PEN, PBT, PA, PVDC, MXD-6, LCP, PAN and SAN.
 11. The spout assembly of claim 1 wherein the base film includes at least one barrier material from the group consisting of EVOH, PET, PETG, PEN, PBT, PA, PVDC, MXD-6, LCP, PAN and SAN.
 12. The spout assembly of claim 1 wherein the upstand further comprises a substantially circular cross-sectional configuration.
 13. A flexible bag assembly comprising: a flexible bag having a plurality of panels that are coupled together with a plurality of seals to form a substantially fluid tight cavity, with an opening providing ingress into the cavity; a spout assembly comprising: a spout having: a base flange with a top surface, a lower surface and an outer surface; an upstand extending from the base flange toward a distal end spaced therefrom, the upstand defining a passageway with a lower opening and an upper opening, the upstand extending through the opening, with the top surface of the base flange coupled to at least one panel of the plurality of panels in a substantially fluid tight configuration about the opening; a base film having: a top surface; a bottom surface, wherein at least a portion of the top surface of the base film overlies at least a portion of the lower surface of the base flange; and a coupling member coupling the base film to the spout, to, in turn, maintain the base film in the overlying orientation.
 14. The flexible bag assembly of claim 13 wherein the coupling member couples the base film to at least one of the lower surface of the base flange, an inner surface of the upstand and a portion of the at least one panel surrounding the opening of the flexible bag.
 15. The flexible bag assembly of claim 13 wherein the base film extends beyond the outer surface of the base flange and overlies a portion of an inner surface of the at least one panel about the opening of the flexible bag.
 16. The flexible bag assembly of claim 13 wherein the base film overlies substantially the entirety of the lower surface of the base flange.
 17. The flexible bag assembly of claim 13 wherein the coupling member is structurally configured to couple the base film directly to the spout.
 18. The flexible bag assembly of claim 17 wherein the coupling member is structurally configured to couple the top surface of the base film directly to the lower surface of the base flange.
 19. The flexible bag assembly of claim 17 wherein the coupling member comprises an adhesive joining the top surface of the base film to the lower surface of the base flange.
 20. The flexible bag assembly of claim 17 wherein the coupling member comprises an inner seal positioned on the bottom surface between an inner annular edge and a projection of the upstand of the spout on the bottom surface, and the outer seal is positioned so as to extend beyond a seal of a film of a bag to the top surface of the base flange. 